Download Manual - EH Wachs

SDB-103 Small Diameter Beveler
and FF 206 Flange Facer
User’s Manual
E.H. Wachs
600 Knightsbridge Parkway
Lincolnshire, IL 60069
www.ehwachs.com
E.H. Wachs Part No. 16-MAN-01
Rev. A, March 2014
Revision History:
Original April 1996
Copyright © 2014 E.H. Wachs. All rights reserved.
This manual may not be reproduced in whole or in part
without the written consent of E.H. Wachs.
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Table of Contents
Table of Contents
Chapter 1: About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How to Use The Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Symbols and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Manual Updates and Revision Tracking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2: Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operator Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Protective Equipment Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 3: Introduction to the Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SDB 103 Small Diameter Beveler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Optional Mandrels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FF 206 Flange Facer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Performance Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operating Envelope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chapter 4: Assembly, Disassembly, and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Storage Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chapter 5: Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setting Up the SDB 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installing the Standard Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installing the Extension Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installing the Small I.D. Conversion Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installing the Independent Fitting Mandrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Mounting the SDB 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Standard and Small I.D. Mandrels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Independent Fitting Mandrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installing and Centering on Elbows and Bends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installing Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cutting the O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cutting the I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Tips for a Good Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FF 206 Flange Facing Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removing the Mandrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Installing the Trip Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
E.H. Wachs
Part No. 16-MAN-01, Rev. Ai
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
FF 206 Independent Fitting Mandrel Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Squaring the FF 206 on Squared Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Squaring the FF 206 on Unsquare Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Mounting the FF 206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FF 206 Flange Facing Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Single-Point Beveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Chapter 6: Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Break-In Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Periodic Inspection Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Chapter 7: Service and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SDB 103 Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Replacing the Front Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
FF 206 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Castle Nut Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Replacing the Feed Screw or Male Tool Slide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Feed Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Chapter 8: Parts Lists and Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Chapter 9: Accessories and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Chapter 10: Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Ordering Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Return Goods Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
ii
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 1, About This Manual
Chapter 1
About This Manual
Purpose of This Manual
This manual explains how to operate and maintain the SDB-103 small diameter beveler (SDB)
and FF 206 flange facer. It includes instructions for set-up, operation, and maintenance. It also
contains parts lists, diagrams, and ser­vice information to help you order replacement parts and
perform user-serviceable repairs.
Before operating the machine, read through this manual and become familiar with all instructions.
How to Use The Manual
This manual is organized to help you quickly find the infor­mation you need. Each chapter describes a specific topic on using or maintaining your equipment.
Use these instructions to operate and maintain the equipment.
E.H. Wachs
Part No. 16-MAN-01, Rev. A1
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Symbols and Warnings
The following symbols are used throughout this manual to indicate special notes and warnings.
They appear in the out­side column of the page, next to the section they refer to. Make sure you
understand what each symbol means, and follow all instructions for cautions and warnings.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
WARNING
A WARNING alert with the safety alert symbol indicates a potentially hazardous situa­tion that could
result in seri­ous injury or death.
CAUTION
A CAUTION alert with the safety alert symbol indicates a potentially hazardous situa­tion that could result
in minor or moderate injury.
A CAUTION alert with the damage alert symbol indicates a situation that will result in
damage to the equipment.
This is the equipment damage alert symbol. It is used to alert you to poten­tial
equipment damage situations. Obey all messages that follow this sym­bol to
avoid damaging the equipment or workpiece on which it is operating.
IMPORTANT
An IMPORTANT alert with the damage alert symbol indi­cates a situation that may result in
damage to the equipment.
NOTE
This symbol indicates a user note. Notes provide additional information to
supple­ment the instructions, or tips for easier operation.
2
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 1, About This Manual: Manual Updates and Revision Tracking
Manual Updates and Revision Tracking
Occasionally, we will update manuals with improved opera­tion or maintenance procedures, or
with corrections if nec­essary. When a manual is revised, we will update the revision history on the
title page.
Current versions of E.H. Wachs Company manuals are also available in PDF for­mat. You can
request an electronic copy of this manual by emailing customer service at [email protected].
You may have factory service or upgrades performed on the equipment. If this service changes any
technical data or operation and maintenance procedures, we will include a revised manual when
we return the equipment to you.
E.H. Wachs
Part No. 16-MAN-01, Rev. A3
EU Declaration OF CONFORMITY
WITH
COUNCIL DIRECTIVE 98/37/EC
Issue Details:
DATE:
4/13/2015
Directives:
Machinery Safety Directive 98/37/EC
Conforming Machinery:
Pipe Beveling & Cut-Off Machines:
Manufacturer:
E.H. Wachs Company
600 Knightsbridge Parkway
Lincolnshire IL 60069
USA
Patrick Fuss
Director of International Sales and Service
Wachs Limited
3 Millbuck Way
Springvale Industrial Estate
Sandbach, Chesire CW11 3JA
United Kingdom
BS EN 292-1:1991, BS EN 292-2: 1991, BS EN 294:1992,
BS EN 349:1998, BS EN 418:1992, BS EN 60204-1:1998
BS EN 982:1996, BS EN 983:1996
Responsible Representative:
Harmonised Standards &
Other Technical
Standards/Specifications
Applied or Referenced:
Provisions with which
Conformity is Declared:
Place:
E.H.Wachs, Lincolnshire, IL USA
Model#: 16, 56, 66, 70, 71, 72-000-XX
Serial #:
Essential Health and Safety Requirements of Annex 1 of
the Machinery Directive
We hereby certify that the machinery described above conforms with the essential
health and safety requirements of Council Directive 98/37/EC on the approximation
of the laws of the Member States relating to the safety of machinery.
Signed:
Signatory:
Pete Mullally
Quality Manager
E.H. Wachs Company
Chapter 2, Safety
Chapter 2
Safety
E.H. Wachs takes great pride in designing and manufactur­ing safe, high-quality products. We
make user safety a top priority in the design of all our products.
Read this chapter carefully before operating the SDB 103/FF 206. It contains important safety
instructions and rec­ommendations.
Operator Safety
Follow these guidelines for safe operation of all E.H. Wachs equipment.
Look for this sym­bol throughout the manual. It indicates a personal injury
hazard.
• READ THE OPERATING MANUAL. Make sure you under­stand all setup and operating instructions
before you begin. Keep this manual with the machine.
• INSPECT MACHINE AND ACCESSORIES BEFORE USE. Before starting the machine, look for loose
bolts or nuts, leak­ing lubricant, rusted components, and any other physi­cal conditions that may
affect operation. Properly maintaining the machine can greatly decrease the chances for injury.
• ALWAYS READ PLACARDS AND LABELS. Make sure all labels, placards and stickers are in place,
clearly legible, and in good condition. Refer to “Safety Labels” later in this chapter for label
locations on the machine. Replace any dam­aged or missing safety labels; see the ordering
informa­tion at the end of this manual.
• KEEP CLEAR OF MOVING PARTS. Keep hands, arms, and fingers clear of all rotating or moving
parts. Always turn the machine off and disconnect the power source before doing any adjustments or service.
E.H. Wachs
Part No. 16-MAN-01, Rev. A5
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
• SECURE LOOSE CLOTHING AND JEWELRY. Secure or remove loose-fitting clothing and jewelry,
and securely bind long hair, to prevent them from getting caught in moving parts of the machine.
• KEEP WORK AREA CLEAR. Keep all clutter and nonessential materials out of the work area. Only
people directly involved with the work being performed should have access to the area.
Safety Symbols
This icon is displayed with any safety alert that indicates a personal injury hazard.
WARNING
This safety alert indicates a potentially hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
This safety alert, with the personal injury hazard symbol, indicates a potentially hazardous situation that,
if not avoided, could result in minor or moderate injury.
Protective Equipment Requirements
For additional information on eye and face protection, refer to Federal OSHA regulations, 29 Code
of Federal Regula­tions, Section 1910.133., Eye and Face Protection and American National
Standards Institute, ANSI Z87.1, Occu­pational and Educational Eye and Face Protection. Z87.1 is
available from the American National Standards Institute, Inc., 1430 Broadway, New York, NY
10018.
WARNING
Always wear impact resistant eye pro­tection while operating or working near this equipment.
Hearing protectors are required in high noise areas, 85 dBA or greater. The operation of other tools
and equipment in the area, reflective surfaces, process noises, and resonant struc­tures can increase
the noise level in the area. For additional information on hearing protection, refer to Federal OSHA
regulations, 29 Code of Federal Regulations, Section 1910.95, Occupational Noise Exposure and
ANSI S12.6 Hearing Protectors.
6
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 2, Safety: Safety Labels
CAUTION
Personal hearing protection is recom­mended when operating or working near this tool.
Safety Labels
The following safety labels are on the SDB 103. If the stick­ers are damaged or missing, replace
them immediately. See Chapter 10 for ordering information.
Figure 2-1. The Caution sticker is on the SDB 103 air motor. Wear ear and eye protection
while operating the machine. (Part number 90-401-03.)
Figure 2-2. The Warning sticker is on the SDB 103. Do not put your hands near the rotating
head while the machine is running. (Part number 66-147-00.)
E.H. Wachs
Part No. 16-MAN-01, Rev. A7
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
8
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 3, Introduction to the Equipment
Chapter 3
Introduction to the Equipment
SDB 103 Small Diameter Beveler
The SDB 103 is a portable pipe prepping machine that can face, bevel, compound bevel, J-prep,
and counterbore open ended pipe and tubing. The handheld SDB 103 mounts on the pipe inside
diameter (I.D.) using a self-centering man­drel clamp system. It will prep open-ended pipe and
tubing from 1.16” to 4.18” I.D. (29.5-106.2 mm), and up to 4.5” (114.3 mm) outside diameter
(O.D.).
The SDB 103 can be easily installed by one operator in just a few minutes. Different sized clamp
leg sets are provided to cover the full range of operation. Select and install the appropriate leg set
for the pipe you are machining, install the tooling, and mount the machine on the pipe using the
simple drawbar mechanism.
An air or electric motor drives the rotating tool head. The operator feeds the tooling into the pipe
face using a manual feed handle. A calibrated feed dial allows precise material removal. The tool
head has three tools slots, allowing mul­tiple facing, beveling, and counterboring operations to be
performed simultaneously.
The machine includes all accessories and tools necessary for operation, and is shipped in a
durable, waterproof stor­age case.
E.H. Wachs
Part No. 16-MAN-01, Rev. A9
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Clamp leg sets
Mandrel
Tool head
Machine body
Feed handle
Air motor
Drawbar
Figure 3-1. The photo shows the SDB 103 compo­nents and accessories.
16-021-07
16-021-01
16-021-06
16-021-02
16-021-03
16-021-05
16-021-04
Figure 3-2. The standard clamp leg sets (identified by part number) fit the standard mandrel
to a range of pipe and tube sizes. See the tables in Chapter 5 for the clamping range for each
leg set.
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Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 3, Introduction to the Equipment: SDB 103 Small Diameter Beveler
Facing tool
26-410-02
10° Deburring tool
26-412-02
37.5° Beveling tool
26-411-01
Counterbore/
facing tool
26-426-00
Figure 3-3. The SDB standard tooling allows the operator to face, bevel, J-prep, and counterbore pipe and tube.
Optional Mandrels
A small-diameter conversion kit (16-401-00) with a smaller mandrel and tool head is available.
The conversion kit allows you to install the machine on pipe I.D.s from 0.875” to 1.75” (22.231.8 mm).
NOTE
Collet-style mandrels are also available for pipe or tube. Call E.H. Wachs customer
service to discuss your application’s requirements.
The standard and small I.D. mandrels automatically center the machine on the I.D. and squares it
to the centerline of the pipe. If you need to mount the machine in a pipe that is on a bend or that has
limited I.D. access, an independent fitting mandrel (16-414-00) with dowel-style clamp legs is
available as an option.
With the independent fitting mandrel, you can adjust the machine to be squared to the pipe end
surface, rather than the centerline. (This mandrel can also be used to mount the FF 206.) A squaring
plate for aligning the machine during installation is provided with the mandrel.
E.H. Wachs
Part No. 16-MAN-01, Rev. A11
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Figure 3-4. The independent fitting mandrel shown in the photo uses dowel-style clamp legs,
shown at right.
Figure 3-5. The squaring plate is used to square the SDB to the pipe face when using the
independent fit­ting mandrel. It is also used for mounting the FF 206.
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Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 3, Introduction to the Equipment: FF 206 Flange Facer
FF 206 Flange Facer
NOTE
The standard FF 206 system does not contain all compo­nents necessary to use it as
an SDB 103. A conversion kit (16-420-00) is available to convert the FF 206 to the
SDB 103.
With the FF 206 conversion kit, the SDB 103 can be quickly converted to a flange facing machine.
The FF 206 will fin­ish raised and flat flange faces from 2.0” (50.8 mm) I.D. up to 6.0” (152 mm)
O.D. The FF 206 can be purchased as a fully integrated machine, or as a kit to upgrade the
SDB 103.
SDB 103 with independent fitting
mandrel and leg sets
Radial tool slide
Tool holder
Trip ring
Squaring plate
Figure 3-6. The photo shows the components of the FF 206, including the SDB 103 machine.
The FF 206 uses a radial-feed tool slide to advance the cut­ting tool across the flange face. A
starwheel on the slide is advanced by striking mechanical trips as the machine rotates. The
starwheel turns a feed screw that drives the slide in the feed direction.
Various finishes can be cut with the FF 206 by varying the number of engaged trips on the trip ring.
Finish options include flange face, record groove, or RMS 63 finish.
E.H. Wachs
Part No. 16-MAN-01, Rev. A13
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Tool holder
Feed screw
Starwheel
Feed
direction
SDB head
mounting
interface
Figure 3-7. The flange facing slide mounts on the SDB 103 to face flanges.
Figure 3-8. The single-point tool holder with tool inserts is used for flange facing.
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Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 3, Introduction to the Equipment: Performance Charts
Performance Charts
The following table is the result of extensive testing. Tests were performed on carbon steel and
stainless steel, as well as exotic materials such as HK40 and incalloys.
Table 1: SDB Application and Performance
Nominal Pipe Size
ASA Pipe Schedule Carbon and Stainless Steel
5 (b)
10 (b)
40
60
80
120
160
3/4”(a)
1”(a)
1 1/4”
1 1/2”
2”
2 1/2”
3”
3 1/2”
4”
(c)
= Effective prepping range
(a) = Limited by mandrel I.D.
(b) = Small I.D. conversion kit required
(c) = Carbon steel only
Table 2: FF 206 Flange Surface Trip Chart
E.H. Wachs
Trips Engaged
RMS Finish
1
63 RMS
2
125 RMS
4
250 RMS
6
500 RMS
Part No. 16-MAN-01, Rev. A15
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Specifications
Machine capacity
SDB 103: Pipe and tube 0.875” (22.2 mm) I.D. to 4.5” (114 mm) O.D.
FF 206: Flange O.D. from 2.0” (51 mm) to 6.0” (152 mm).
Machining functions
(SDB 103)
Facing, O.D. beveling, compound beveling, J prepping, and I.D. counterboring of openend pipe and tube. Use up to four tools simultaneously.
Machining functions
(FF 206)
Single-point finishing of flat and raised flange faces. Surface finishes include 500 RMS
(record groove), 250 RMS, 125 RMS, and 63 RMS.
Mounting mechanism
I.D.-mounted mandrel with adjustable clamping legs and multiple legs sets to cover full I.D.
range. Standard diameter, small I.D., and independent fitting (short clearance) mandrels
available.
Drive motors
Air motor, 110 V or 220 V electric motor
Air requirements
16-000-01: 35 cfm (991 l/min)
Electrical requirements
16-000-02: 110 VAC, 50-60 Hz, 8.0 A
16-000-03: 220 VAC 50-60 Hz, 4.6 A
Controls
Manual clamping, manual axial feed, vari­able speed control (air or electric). FF 206:
mechanical radial feed using starwheel/trip mechanism.
Feed features
2.5” (63.5 mm) maximum axial feed; 0.0625” (1.59 mm) feed per handle revolu­tion.
Indexed feed dial for precise depth.
Tooling
Standard Wachs form tools for facing, bev­eling, and counterboring. Single-point holder
with inserts for FF 206 flange facing. High speed steel or carbide. Custom tool­ing
available.
Dimensions and weights
See operating envelope drawings in next section.
Operating Envelope
The following drawings illustrate the overall dimensions and operating envelopes for the SDB 103
with air and elec­tric motors, and for the FF 206.
16
Part No. 16-MAN-01, Rev. A
E.H. Wachs
E.H. Wachs
NOTE:
SEE 16-409-00 FOR EXTENSION
LEG CLAMPING RANGES
1.57 MAX
39.9
1.16 MIN
29.6
DETAIL-A
LEGS SHOWN FULLY EXTENDED
LEGS SHOWN FULLY RETRACTED
4.75
120.7
DIMENSIONS IN BRACKETS ARE MILLIMETERS
2.46
62.5
1.28
32.6
6.26
159.0
SDB 103 Operating Envelope
1.28 REF
32.6
LEGS SHOWN FULLY RETRACTED
SEE DETAIL-A
3.36 MAX
85.3
TRAVEL
5.29
134.5
26-410-02
FACING TOOL
.75
19.1
16.75 MAX
425.5
3.25 REF
82.5
12.33
313.1
3.19
81.0
Chapter 3, Introduction to the Equipment: Operating Envelope
Part No. 16-MAN-01, Rev. A17
18
Part No. 16-MAN-01, Rev. A
NOTE:
SEE 16-409-00 FOR EXTENSION
LEG CLAMPING RANGES
1.57 MAX
39.9
1.16 MIN
29.6
4.75
120.7
DETAIL-A
LEGS SHOWN FULLY EXTENDED
LEGS SHOWN FULLY RETRACTED
DIMENSIONS IN BRACKETS ARE MILLIMETERS
2.46
62.5
1.28
32.6
6.26
159.0
3.36 MAX
85.3
TRAVEL
5.29
134.5
16-000-02 and 16-000-03
SDB 103 Operating Envelope
1.28 REF
32.6
LEGS SHOWN FULLY RETRACTED
SEE DETAIL-A
26-410-02
FACING TOOL
.75
19.1
16.75 MAX
425.5
19.24 REF
488.7
10.07 REF
255.7
6.69
169.8
3.19
81.0
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
E.H. Wachs
E.H. Wachs
.97 MIN
24.7
.87 MIN
22.1
DIMENSIONS IN BRACKETS ARE MILLIMETERS
1.25MAX
31.7
1.11 MAX
28.3
CLAMPING RANGE
3.13 REF
79.4
2.70 MAX
68.6
TRAVEL
SDB 103 Operating Envelope
Small I.D. Conversion Kit, 16-401-00
LEGS (16-068-00) SHOWN FULLY RETRACTED
AND
WITHOUT O-RING (16-070-02)
LEGS (16-067-00) SHOWN FULLY RETRACTED
AND
WITHOUT O-RING (16-070-01)
2.43 MAX
61.7
TRAVEL
Chapter 3, Introduction to the Equipment: Operating Envelope
Part No. 16-MAN-01, Rev. A19
R6.63
168.3
SWING
20
Part No. 16-MAN-01, Rev. A
6.19
157.1
FF 206 Operating Envelope
1.77 REF
45.0
DIMENSIONS IN BRACKETS ARE MILLIMETERS
16-042-00
TOOL HOLDER
60-702-00
INSERT TOOL
.38
9.5
4.23 MAX
107.3
TRAVEL
3.14
79.9
.33
8.3
14.07
357.3
6.26
159.0
3.25 REF
82.5
12.33
313.1
.25
6.4
THREAD ENGAGEMENT
ON MANDREL
3.19
81.0
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
E.H. Wachs
Chapter 4, Assembly, Disassembly, and Storage
Chapter 4
Assembly, Disassembly, and
Storage
The SDB 103 comes fully assembled and ready to operate. See the instructions in Chapter 5 for
configuring clamp legs, mandrels, and tool heads for various applications. Instructions are also
provided for converting the SDB 103 to the FF 206 flange facer.
The SDB 103 and FF 206 are shipped in custom-configured storage cases. Keep the machines in
their cases when not in use. Figure 4-1 and Figure 4-2 show the machines in their cases.
SDB 103
Clamp leg sets
Hand tools
Figure 4-1. The photo shows the SDB 103 in its case.
E.H. Wachs
Part No. 16-MAN-01, Rev. A21
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
FF 206
trip ring
Squaring
plate
Hand
tools
Tool holder
and inserts
FF 206 slide
SDB 103 machine with
inde­pendent fitting mandrel
Clamp leg sets
Figure 4-2. The photo shows the components of the FF 206, including the SDB 103 machine,
in its storage case.
Storage Checklist
Before storing the SDB 103 or FF 206, perform the follow­ing maintenance steps:
• Put oil in the air motor oiler, and operate the motor for a few seconds to lubricate its internal
components.
• Apply grease to the grease fitting on the SDB machine body.
• Rub a coating of light oil on the drawbar and mandrel.
• Rub a coating of oil on the feed screw of the FF 206 slide.
• Oil the dovetail surfaces on the FF 206 slide.
• If you will be storing the machine longer than 30 days, put desiccant packets in the case to
prevent corrosion.
22
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions
Chapter 5
Operating Instructions
Pre-Operation Checklist
To avoid damaging the equipment, follow these usage guidelines.
1.
Inspect the bore of the rotating head for dirt and metal chips. Clean the bore with compressed
air or solvent as necessary.
2.
Wipe the mandrel clean, and apply a light coating of oil.
Figure 5-1. When cleaning the mandrel, inspect the threads for damage.
3.
Lubricate the machine according to the guidelines in Chapter 6.
E.H. Wachs
Part No. 16-MAN-01, Rev. A23
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Setting Up the SDB 103
Installing the Standard Mandrel
NOTE
You do not normally need to remove the mandrel from the machine. Use this
procedure if the mandrel has been removed for service or re-configuring the SDB 103.
These instructions are for installing the standard mandrel on the SDB 103. For instructions on the
optional mandrels, see “Installing the Small I.D. Conversion Kit” and “Installing the Independent
Fitting Mandrel” later in this section.
1.
Insert the threaded end of the mandrel through the front of the rotating head. Be careful not to
damage the head bushing.
Figure 5-2. If it is not already installed, insert the mandrel through the tool head as shown.
2.
Align the keyway slots of the mandrel with the inter­nal keys of the beveling head.
3.
Insert the mandrel until it stops. Rotate the feed handle clockwise to engage the threads into
the feed nut, and continue feeding until the mandrel shaft is approxi­mately ¾” (19 mm)
beyond the end cap.
24
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: Setting Up the SDB 103
Figure 5-3. Turn the feed handle to thread the man­drel into the machine body
NOTE
The drawbar nut and the collar nut must be removed to remove the mandrel from the
machine body.
4.
Install the draw bar nut, and then install and tighten the collar nut. The collar nut captivates
the draw bar nut so the draw bar nut can be turned to expand and contract the mandrel legs.
Figure 5-4. Tighten the collar nut with finger pressure to captivate the draw bar nut on the
mandrel.
E.H. Wachs
Part No. 16-MAN-01, Rev. A25
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Installing the Extension Legs
Install the appropriate leg set to fit the pipe you are machin­ing. Table 1 gives the I.D. range for each
leg set provided with the SDB 103 standard mandrel.
Table 1: Standard Mandrel Extension Legs
1.
Leg Set
Thickness
I.D. Range
None
N/A
1.16–1.57” (37.8–39.8 mm)
16-021-01
0.218” (5.5 mm)
1.53–1.94” (38.8–49.25 mm)
16-021-02
0.405” (10.2 mm)
1.90–2.32” (48.2–58.9 mm)
16-021-03
0.592” (15.0 mm)
2.27–2.69” (57.6–68.7 mm)
16-021-04
0.780” (19.8 mm)
2.64–3.06” (67.0–77.7 mm)
16-021-05
0.968” (24.5 mm)
3.02–3.43” (76.7–87.1 mm)
16-021-06
1.155” (29.3 mm)
3.39–3.81” (86.1–96.7 mm)
16-021-07
1.343” (34.1 mm)
3.76–4.18” (95.5–106.1 mm)
To determine which leg set is required, measure the work piece pipe I.D. and refer to the
extension leg chart in Table 1.
Figure 5-5. Use a scale to measure the I.D. of the pipe.
26
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: Setting Up the SDB 103
Figure 5-6. Each leg set is stamped with a reference number which corresponds to the pipe
I.D. range the leg set will accommodate.
2.
Select the required extension leg set. The extension legs each have two captivated screws
used to fasten them to the mandrel legs.
3.
Tighten the captivated screws on the extension legs to attach the extension legs to the mandrel legs.
Figure 5-7. Attach the clamp legs to the mandrel and tighten the 2 screws in each leg.
Installing the Small I.D. Conversion Kit
The small I.D. conversion kit (part number 16-401-00) allows you to install the SDB 103 on pipe
I.D.s down to 0.875” (22.2 mm). The kit includes a thinner mandrel and a tool head with a smaller
bore. Use the following procedure to replace the standard mandrel and tool head.
1.
Loosen and remove the collar nut and drawbar nut on the standard mandrel.
2.
Turn the feed handle counter-clockwise until you can remove the standard mandrel through
the tool head of the SDB 103.
E.H. Wachs
Part No. 16-MAN-01, Rev. A27
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
3.
Remove the standard tool head from the SDB 103 by taking out the 4 screws holding it.
4.
Remove the clamp legs on the small I.D. mandrel.
5.
Remove the drawbar nut and drawbar from the small I.D. mandrel.
6.
Insert the small I.D. mandrel into the machine body. Position the mandrel so that the keyways
are aligned with the keys in the machine, and turn the feed handle clockwise to thread the
mandrel into the feed nut.
7.
Slide the small I.D. rotating head over the end of the mandrel. Install it on the machine body
with the 4 screws.
8.
Measure the pipe I.D. and select the appropriate leg set and o-ring to fit. Make sure to use the
correct o-ring for the leg set you are using. Refer to Table 2 below.
9.
Install the legs onto the drawbar chuck, using the o-ring to hold them in place.
10. Insert the small I.D. drawbar through the mandrel and re-install the drawbar nut.
NOTE
When returning legs to their proper position in the mandrel assembly, the O ring that
secures them must be in the correct position prior to reinstalling the draw bar assembly.
The O ring will not slip over the end of the draw bar once it has been installed.
Table 2: Small-Diameter Mandrel Extension Legs
Leg Set
I.D. Range
O-Ring
16-067-00
0.875–1.125” (22.2–28.6 mm)
16-070-01
16-068-00
1.00–1.250” (25.4–31.8 mm)
16-070-02
Installing the Independent Fitting Mandrel
If the pipe you are machining has an obstruction or bend that does not allow enough room for the
standard mandrel to mount, use the independent fitting mandrel instead. Follow this procedure to
install the independent fitting mandrel.
The independent fitting mandrel is not self-squaring. You will need to use the squaring plate
provided with it to square the machine to the pipe face.
1.
If necessary, remove the standard mandrel from the SDB 103.
2.
Insert the independent fitting mandrel through the tool head until it stops. Position the mandrel so that the keyways are aligned with the keys in the machine, and turn the feed handle
clockwise to thread the mandrel into the feed nut.
3.
Measure the pipe I.D., and select the extension leg set required. Refer to the extension leg
chart in Table 3 below.
28
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: Setting Up the SDB 103
Table 3: Independent Fitting Mandrel Extension Legs
4.
Part Number
(Solid/adjustable)
Length
(Solid/Adjustable)
Min. Diameter
Max. Diameter
16-053-01
N/A
0.0794” (20.1 mm)
N/A
1.95”
(49.5 mm)
2.31”
(58.6 mm)
16-053-02/
16-054-02
0.944” (23.9 mm)
0.824” (20.9 mm)
2.25”
(57.1 mm)
2.61”
(66.2 mm)
16-053-03/
16-054-03
1.094” (27.7 mm)
0.974” (24.7 mm)
2.55”
(64.7 mm
2.91”
(73.9 mm)
16-053-04/
16-054-04
1.244” (31.5 mm)
1.124” (28.5 mm)
2.85”
(72.3 mm)
3.21”
(81.5 mm)
16-053-05/
16-054-05
1.394” (35.4 mm)
1.274” (32.3 mm)
3.15”
(80.0 mm)
3.51”
(89.1 mm)
16-053-06/
16-054-06
1.544” (39.2 mm)
1.424” (66.1 mm)
3.45”
(87.6 mm)
3.81”
(96.7 mm)
16-053-07/
16-054-07
1.694” (43.0 mm)
1.574” (39.9 mm)
3.75”
(95.2 mm)
4.11”
(104.3 mm)
Insert the legs into the mandrel head. The adjustment screw in the adjustable leg must be
completely screwed in.
Figure 5-8. Attach the leg adjustment screw to the adjustable leg and screw it in fully.
E.H. Wachs
Part No. 16-MAN-01, Rev. A29
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Figure 5-9. Insert the legs into the independent fitting mandrel.
30
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: Mounting the SDB 103
Mounting the SDB 103
Standard and Small I.D. Mandrels
1.
Insert the mandrel chuck into the pipe. For best results, keep the end of the chuck legs close
to the pipe edge.
NOTE
The maximum depth of pene­tration into the pipe should be ¾” (19 mm) from the rear
of the mandrel legs to the pipe edge. This will allow for a nor­mal prep and still keep
the machine body and rotating head stable.
Figure 5-10. Insert the mandrel into the pipe.
2.
Hold the machine with the mandrel at the desired clamping location.
NOTE
Torque the drawbar nut to 25 lb-ft.
3.
Rotate the draw bar nut with the supplied wrench to expand the mandrel legs into the I.D. of
the pipe. The chuck legs will automatically center the machine to the pipe.
E.H. Wachs
Part No. 16-MAN-01, Rev. A31
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Figure 5-11. Hold the machine in place and tighten the drawbar nut.
Independent Fitting Mandrel
1.
Set the mandrel assembly, with the required leg set installed, into the pipe.
NOTE
You can install the indepen­dent fitting mandrel in the pipe before putting it on the
SDB 103 or FF 206 machine. The mandrel may be easier to square without the SDB
103 attached.
32
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: Mounting the SDB 103
Figure 5-12. Insert the mandrel into the pipe.
2.
Put the squaring plate over the shaft of the mandrel and slide it against the head. Pull the
mandrel back in the pipe if necessary.
Figure 5-13. Put the squaring plate onto the mandrel.
E.H. Wachs
Part No. 16-MAN-01, Rev. A33
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
3.
Tighten the set screws in the squaring plate to secure it to the mandrel.
Figure 5-14. Tighten both set screws in the squaring plate to secure and center it to the
mandrel.
4.
Push the mandrel into the pipe so that the squaring plate is pressed tight against the pipe face.
Tighten the drawbar nut while holding the mandrel in this posi­tion.
5.
Loosen the set screws in the squaring plate and remove the plate from the mandrel. Check the
location of the legs in the pipe.
Figure 5-15. The mandrel legs should be close to the edge of the pipe.
6.
34
If you need to install the SDB 103 or FF 206 on the mandrel, slide the tool head over the
mandrel and position the machine to line up the keys and the key­way slots. Turn the feed handle clockwise to thread the mandrel into the machine.
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: Mounting the SDB 103
Installing and Centering on Elbows and Bends
1.
When inserting the mandrel into the pipe, position the adjustable leg at the “short radius
bend” side of the pipe. Make sure the screw on the adjustable leg is screwed all the way in.
Measurement “B”
ADJUSTABLE LEG
Measurement “A”
Short radius bend
Figure 5-16. Install the mandrel with the adjustable leg positioned at the short radius bend
of the pipe.
2.
Using the squaring plate as described in the previous section, snug the drawbar nut to hold
the mandrel in place. Remove the squaring plate.
NOTE
If the end of the pipe is not square, you will have to establish a reference point for
squaring.
3.
Measure the distance over the adjustable leg from the pipe I.D. to the mandrel shaft. Write
this number down as measurement “A”.
4.
At the position 180° across from the adjustable leg, measure the distance from the pipe I.D.
to the mandrel shaft. Write this number down as measurement “B”.
• If the two measurements are close enough for the toler­ance of your application, you do not
need to adjust the centering.
• If you need to re-center the mandrel, you will have to remove the it and adjust the screw in the
adjustable leg.
• Subtract measurement “A” from measurement “B” and divide the result by 2. This is the
required adjustment distance; write it down as “C”.
B – A = C
2
• One turn of the adjustment screw extends the screw by 0.035" (0.89 mm). Divide “C” by this
amount to deter­mine how many turns to adjust the screw.
E.H. Wachs
Part No. 16-MAN-01, Rev. A35
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Turns = C
0.035"
5.
Before removing the mandrel, attach the squaring plate to it with the plate firmly against the
pipe face. Loosen the drawbar nut to remove the mandrel.
6.
Turn the adjustment screw the number of turns you calculated above.
NOTE
This procedure assumes that the pipe radius is greater at the “short radius bend”
side of the pipe (measurement “A”). If the radius is greater on the other side
(measure­ment “B”), adjust the leg as described, but re-install the mandrel with the
adjustable leg in the opposite direction.
7.
With the squaring plate still on the mandrel, re-install the mandrel on the pipe and tighten the
drawbar nut.
8.
Remove the squaring plate and repeat the “A” and “B” measurements. If necessary, re-adjust
the centering using the same procedure.
Installing Tooling
Refer to the tool selection chart to select the appropriate tooling.
1.
Loosen the tool bit wedge screw.
2.
Install the facing tool in the rotating head slot.
Direction
of rotation
Align tool with
pipe face
Figure 5-17. Position the tooling so the tool bit com­pletely contacts the pipe face.
3.
Install the beveling tool in the rotating head slot.
4.
All tool bits must be installed so the cutting edge is facing clockwise as seen from the manual
feed handle.
36
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: Cutting the O.D.
Figure 5-18. Direction of rotation is indicated by the arrow.
5.
Tighten the tool bit wedge screws to secure the tools in place.
Cutting the O.D.
1.
Connect the drive motor to the motor adapter. Tighten the screws holding the motor in place.
IMPORTANT
An air treatment module (ATM) with an inline air oiler / moisture separa­tor is required for
proper lubrication and operation of the SDB air motor. Machine life can be shortened and
the warranty can be voided if an ATM is not used. An ATM can be purchased from E.H.
Wachs or a third party.
2.
Connect power (air or electric) to the drive motor.
3.
Start the machine, and turn the manual feed handle clockwise until the cutting tools contact
the pipe.
E.H. Wachs
Part No. 16-MAN-01, Rev. A37
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Figure 5-19. To face the pipe, turn the feed handle clockwise.
4.
Continue operating the machine until the pipe has a clean finish.
5.
When the desired finish is complete, turn the feed han­dle counter-clockwise to retract the tool
away from the pipe face. Turn off the drive motor.
6.
Retract the tool head fully by turning the manual feed handle counter-clockwise.
Figure 5-20. Retract the tooling after the operation is complete by turning the feed handle
counter-clock­wise.
7.
38
Disconnect the power source from the drive motor.
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: Cutting the I.D.
Cutting the I.D.
1.
Loosen the tool bit wedge screw, and remove the fac­ing tool.
2.
Insert the counterbore tool.
Figure 5-21. Insert the counterbore tool but do not snug the tool bit wedge screws.
3.
Measure the desired counterbore radius and land thickness.
Figure 5-22. Use a scale to properly position the counterbore tool.
4.
Adjust the counterbore tool appropriately.
5.
Loosen the opposite tool bit wedge screw.
E.H. Wachs
Part No. 16-MAN-01, Rev. A39
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
NOTE
Once the cutting tools are in place, the machine can be moved from one pipe to
another of the same size without resetting the tool bits. The same land, bevel, and
I.D. bore will be cut on all subsequent pipes.
6.
Insert the I.D. deburring tool into the slot opposite the beveling tool. Adjust the tool to produce the desired I.D. size and depth.
7.
Tighten both tool bit wedge screws.
8.
Start the machine.
9.
Turn the manual feed handle clockwise until the coun­terbore tool contacts the pipe.
Figure 5-23. Run the machine until the desired coun­terbore is cut.
10. Operate the machine until the counterbore is com­plete.
Tips for a Good Finish
1.
Set the mandrel legs as close to the pipe end as possi­ble while leaving enough space between
the edge and the clamp legs to complete the operation.
2.
Whenever possible, use cutting oil or coolant. Using cutting oil or coolant will lengthen tool
life.
3.
Feed the tool into the workpiece slowly so tool touch-off can occur without damage. Once
the tool has cut a full 360 degrees, regulate the speed and feed for best performance. Different materials will require different feed speeds for optimum performance.
40
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: Cutting the I.D.
4.
Adjust cutting head RPM depending on the material. The harder the material, the slower the
speed should be.
Decrease
Increase
Figure 5-24. Turn the air motor throttle clockwise to increase RPM and counter-clockwise to
decrease RPM.
5.
Keep uniform pressure on the feed handle until the prep is complete.
6.
Retract the tool bits quickly by turning the feed handle counterclockwise when the prep is
finished.
Figure 5-25. Turn the feed handle counter-clockwise as shown to retract the tool bits.
E.H. Wachs
Part No. 16-MAN-01, Rev. A41
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
7.
Use the calibrated feed handle for precise cuts.
Figure 5-26. The calibrated feed handle is graduated in 1/1000” increments.
42
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: FF 206 Flange Facing Setup
FF 206 Flange Facing Setup
Removing the Mandrel
1.
Remove the collar nut and drawbar nut from the end of the mandrel shaft.
2.
Turn the feed handle counter-clockwise until the man­drel shaft disengages from the feed nut.
Figure 5-27. Remove the drawbar nut before remov­ing the mandrel.
3.
Pull the mandrel shaft through the front of the rotating tool head.
Figure 5-28. Pull the mandrel out through the tool head.
4.
Remove the four screws retaining the rotating tool head, and remove the rotating head.
E.H. Wachs
Part No. 16-MAN-01, Rev. A43
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Figure 5-29. Remove the rotating head screws using a 3/16” hex wrench.
Installing the Trip Collar
1.
Install the trip collar assembly. The locking screw must be located close to the air motor
housing. Instal­lation at this position will ensure access to each trip.
NOTE
Do not remove the two screws under the feed screw.
Figure 5-30. The trip collar locking screw should be as close to the air motor housing as
possible.
44
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: FF 206 Flange Facing Setup
2.
Tighten the trip collar screws.
3.
Place the flange facing module over the machine housing face and align the mounting holes.
The felt washer must be installed on the back of the module.
Figure 5-31. Align the mounting screws with the rotating head holes.
4.
Tighten the four mounting screws with the provided hex key set.
5.
Insert the mandrel assembly into the machine body.
6.
Attach the drawbar nut and the collar nut to the end of the mandrel shaft.
E.H. Wachs
Part No. 16-MAN-01, Rev. A45
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
FF 206 Independent Fitting Mandrel Setup
1.
Measure the flange I.D., and select extension leg set required.
Figure 5-32. Measure the I.D. of the flange.
2.
Insert legs into mandrel head. The leg adjustment screw must be completely tightened
against the leg face.
NOTE
Set up the inde­pendent fitting mandrel with the machine body removed.
46
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: FF 206 Independent Fitting Mandrel Setup
Figure 5-33. Attach the leg adjustment screw to the adjustable leg.
3.
Insert the mandrel into the flange.
Squaring the FF 206 on Squared Flange
1.
Place the alignment fixture over the mandrel shaft.
2.
Slide the alignment fixture firmly against the flange face.
3.
Tighten the two brass-tipped screws to lock the align­ment fixture in place.
Figure 5-34. The squaring plate automatically squares the FF 206 to the pipe face.
E.H. Wachs
Part No. 16-MAN-01, Rev. A47
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
4.
Tighten the drawbar nut.
Figure 5-35. Tighten the drawbar nut to clamp the mandrel in the flange I.D.
5.
Remove the alignment fixture. The mandrel and machine are now square to the flange face.
Squaring the FF 206 on Unsquare Flange
If the elbow or bend is not square, establish a reference point for squaring, and then square the
machine to that point using the procedure detailed above.
48
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: FF 206 Flange Facing Operating Procedure
Mounting the FF 206
1.
Slide the machine housing over the threaded end of the mandrel.
Figure 5-36. Install the configured FF 206 onto the mandrel.
2.
Turn the feed handle clockwise to engage the mandrel threads.
FF 206 Flange Facing Operating Procedure
1.
Rotate the starwheel and retract the tool slide until the tool holder slot is beyond the O.D. of
the flange.
NOTE
The independent fitting mandrel with the alignment fixture is recommended for
optimum centering and squaring.
E.H. Wachs
Part No. 16-MAN-01, Rev. A49
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Figure 5-37. Turn the starwheel counter-clockwise to retract the tool slide past the O.D. of
the flange.
2.
Install the single point tool holder and cutting tool. Tighten the tool positioning screws.
NOTE
The FF 206 rotates clockwise as viewed from the rear of the machine. The cutting
edge of the tool must face clock­wise to cut.
Figure 5-38. Position the single point cutting tool with the cutting surface in the direction of
rotation.
50
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: FF 206 Flange Facing Operating Procedure
3.
Time the starwheel by setting it so that one of its points is perpendicular to the flange face.
4.
Engage the number of trips required for the desired surface finish, as described in Table 4.
Table 4: FF 206 Flange Surface Trip Chart
Trips Engaged
RMS Finish
1
63 RMS
2
125 RMS
4
250 RMS
6
500 RMS
Figure 5-39. Flip the trip lever up to engage the trip.
5.
Turn the flange facer by hand until the starwheel reaches an engaged trip. Ensure that the
starwheel will strike the trip as the machine rotates.
6.
Set the tool bit depth by turning the manual feed han­dle. Use the calibration label on the
machine body to set the depth precisely.
E.H. Wachs
Part No. 16-MAN-01, Rev. A51
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Figure 5-40. Turn the feed handle clockwise to set the tool bit depth.
7.
Gently snug the set screw on the back of the feed han­dle to prevent the machine from feeding
radially dur­ing operation.
Figure 5-41. Snug the feed handle set screw to keep the machine from moving radially when
flange facing.
8.
Connect the power supply (air or electric) to the drive motor.
9.
Engage the power switch on the motor and operate the machine slowly, making sure the
starwheel strikes each engaged trip.
52
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: Single-Point Beveling
10. Operate the machine until the tool feeds in to the O.D. of the flange surface. Once the tool has
cut a full 360 degrees, regulate the speed and feed for best perfor­mance. Different materials
will require different feed speeds for optimum performance.
11. When the flange surface has been completely sur­faced, stop the machine.
12. Loosen the set screw on the back of the feed handle, and turn the handle counter-clockwise to
retract the tool.
Figure 5-42. Retract the tool by turning the feed han­dle counter-clockwise.
Single-Point Beveling
Using the FF 206, you can bevel a pipe face with a single-point tool. As the machine rotates and the
radial feed advances the tool automatically, turn the manual feed han­dle counter-clockwise to
withdraw the tool and create the bevel profile. Follow the procedure below, using the infor­mation
in Table 5.
NOTE
The FF 206 with a singlepoint tool will allow you to bevel heavier walled pipe than is
possible using the SDB 103 with form tooling.
1.
Calculate the starting axial position (cutting depth) on the O.D. of the pipe. Use the
“Tangent” value in Table 5 for the bevel angle you are performing, and refer to the drawing in
Figure 5-43.
E.H. Wachs
Part No. 16-MAN-01, Rev. A53
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
NOTE
EXAMPLE:
T = 0.75”
A = 20°
D = tangent(20°) x 0.75”
= 0.364 x 0.75” = 0.273”
D
Starting axial position
A
T
Pipe O.D.
Pipe
wall
Pipe I.D.
A = Bevel angle
T = Thickness of pipe wall
D = Depth of cut
D = tangent(A) x T
Figure 5-43. Use the pipe thickness and the bevel angle to calculate the starting depth of cut
(D). Refer to Table 5 for tangents of common bevel angles.
2.
The maximum depth you can cut at one time is about 0.300” (7.6 mm). If the number you
calculated for D is greater than that, divide D by 0.300 (or 7.6 if metric) to determine the
number of passes to make.
NOTE
A cutting depth of 0.300” (7.6 mm) is possible under ideal circumstances. You may
need to cut smaller passes if the pipe material is especially hard or if you are cutting
a coarse finish.
D
Cut multiple
passes if D
is too thick
to cut in one
pass
Figure 5-44. Cut multiple passes if necessary.
54
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 5, Operating Instructions: Single-Point Beveling
3.
Engage the number of trips required for the surface finish desired. Refer to Table 4 earlier in
this chapter.
4.
Refer to Table 5 for the required axial feed rate for the number of trips you are using. This is
the distance you will need to retract the
NOTE
EXAMPLE:
To cut a 30° bevel with 6 trips engaged, you must withdraw the cutting tool .018”
each time the cutting tool com­pletes a revolution (turning the feed handle counterclockwise). Use the cali­brated feed label on the feed handle assembly.
Table 5: Axial Feed Rate
Bevel
Angle
Tangent
10o
Trips Engaged
1
2
3
4
0.176
.001”
(.03 mm)
.002”
(.05 mm)
.004”
(.10 mm)
.006”
(.15 mm)
20o
0.364
.002”
(.05 mm)
.004”
(.10 mm)
.008”
(.20 mm)
.011”
(.28 mm)
30o
0.577
.003”
(.08 mm)
.006”
(.15 mm)
.012”
(.30 mm)
.018”
(.46 mm)
37.5o
0.767
.004”
(.10 mm)
.008”
(.20 mm)
.016”
(.41 mm)
.024”
(.61 mm)
5.
With the FF 206 set up as described earlier in this chapter, turn the feed handle clockwise
until the tool bit just touches the pipe face.
6.
Turn the starwheel on the radial slide counter-clock­wise until the tool bit is past the O.D. of
the pipe face.
7.
Turn the feed handle clockwise to advance the tool bit to the desired cutting depth. If you are
cutting multiple passes, advance it to the position of the first pass.
8.
Start the machine and allow the radial slide to advance until the tool contacts the O.D. of the
pipe.
9.
When the tool touches the O.D., start turning the feed handle counter-clockwise by the
required feed rate from Table 5. Refer to the calibrated feed label.
10. Operate the machine until the pass is complete and the tool is no longer engaged with the
pipe surface. Turn off the machine.
11. If you need to cut another pass, reset the tool position to the required location on the O.D. of
the pipe. Repeat the required number of passes.
E.H. Wachs
Part No. 16-MAN-01, Rev. A55
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
56
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 6, Routine Maintenance
Chapter 6
Routine Maintenance
Break-In Period
After the first 10 hours of operation, you should check the pre-load on the main shaft bearings of
the SDB 103, and adjust if necessary.
1.
Remove the drive motor from the machine.
2.
Remove the mandrel and drawbar.
3.
Remove the 4 screws holding the feed housing assem­bly (16-302-00) and remove the
assembly.
Feed housing ass’y
screws (3 shown)
Figure 6-1. Remove the 4 screws attaching the feed housing assembly.
4.
Insert and tighten an old tool bit in one slot of the cut­ting head.
E.H. Wachs
Part No. 16-MAN-01, Rev. A57
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
5.
Set the tool head down onto a bench vise and clamp the tool bit in it to secure the machine
body.
NOTE
A Wachs assembly tool (AT16-05) is available to tighten the lock nut.
6.
Using a spanner wrench, tighten the lock nut while rotating the main housing until you can
feel a slight drag. Back the lock nut off 1/4 turn.
7.
Remove machine from vise and remove the tool bit from the cutting head.
8.
Replace the feed housing assembly and the 4 screws holding it. Do not tighten the screws yet.
9.
Install the drive motor.
10. Insert the mandrel into the machine and turn the feed handle clockwise to engage the feed
screw through the feed nut housing. This will ensure proper feed nut housing alignment with
the mandrel.
11. Tighten the 4 screws holding the feed housing assem­bly.
Periodic Inspection Checklist
• The bevel gear sets and roller bearing should be inspected every 100 hours of operation and
lubricated as needed.
• Check the main shaft bearings every 10 hours of opera­tion. Remove the air motor, feed housing
assembly, and four screws. Refer to the exploded view drawings in Chapter 8 for details.
• Every 10 hours of operation, inspect the front bushing for signs of wear. Excessive chatter may
indicate a worn front bushing. If necessary, replace the bushing using the procedure in
Chapter 7.
• Inspect the mandrel threads for signs of wear every 10 hours of operation. Replace the mandrel
if the mandrel threads are damaged.
58
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 6, Routine Maintenance: Lubrication
Lubrication
1.
The bore of the cutting head, feed nut, and mandrel must be kept clean and oiled.
2.
Fill the air treatment module with motor oil or anti­freeze motor oil.
Figure 6-2. Apply air motor oil to the air motor daily.
3.
Every 40 hours of operation, flush the air motor with a solution of three parts cleaning solvent
and one part air motor oil. Afterwards, add 1 oz. of air motor oil into the air line and run the
air motor for one minute.
4.
The components of the mandrel, including the draw­bar and clamp legs, should be cleaned
and oiled every day of use.
Figure 6-3. When cleaning the mandrel, inspect the threads for damage.
E.H. Wachs
Part No. 16-MAN-01, Rev. A59
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
60
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 7, Service and Repair
Chapter 7
Service and Repair
SDB 103 Service
Use the following procedures for service and repair of the SDB 103 machine components.
Replacing the Front Bushing
Replace the front bushing (16-030-00) if it shows wear or damage.
1.
Remove the mandrel from the machine.
2.
Remove the 4 screws holding the tool head and remove the head from the machine.
3.
Insert a 1.25” diameter drift pin from the rear of the main shaft and use it drive out the old
bushing.
4.
Place the new bushing on a bushing driver (part # 16-033-00 available from E.H. Wachs),
and press it into the main shaft until the edge of the bushing is flush with the front of the
shaft.
5.
Replace the tool head and the mandrel.
E.H. Wachs
Part No. 16-MAN-01, Rev. A61
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
FF 206 Service
Use the following procedures for service and repair of the components specific to the FF 206 flange
facer.
Castle Nut Adjustment
If there is excess backlash in the feed screw, adjust it by adjusting the castle nut tight against the
starwheel.
1.
Using a punch, drive out the pin holding the castle nut on the feed screw.
Castle
nut
Pin
Figure 7-1. Take out the pin holding the castle nut to turn the nut.
2.
Turn the castle nut by hand clockwise to snug it against the starwheel.
3.
Replace the pin in the feed screw, holding the castle nut at the tightest location at which you
can put the pin through it. Tap the pin in with a hammer until it is flush with the sides of the
castle nut.
Replacing the Feed Screw or Male Tool Slide
If the feed screw or male tool slide is damaged or becomes worn, replace them according to the
following procedure.
1.
Set the FF 206 slide on a workbench or table.
2.
Turn the starwheel counter-clockwise to retract the male tool slide until it comes off the end
of the feed screw.
62
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 7, Service and Repair: FF 206 Service
3.
Using a punch, drive out the pin holding the castle nut on the feed screw. (See “Castle Nut
Adjustment” above.)
4.
Turn the castle nut off the end of the feed screw.
5.
Pull the starwheel off the end of the feed screw and remove the Woodruff key from the slot in
the screw.
6.
Pull the feed screw out through the back of the feed screw block.
7.
Inspect the feed screw and male tool slide for damage to the thread or signs of wear. Replace
either or both if necessary.
8.
To re-assemble the slide, reverse this procedure. Make sure the castle nut is snug against the
starwheel before re-installing the pin through the feed screw.
Feed Tension Adjustment
An adjustable gib that holds the male tool slide lets you adjust the feed tension. Check the tension
by turning the starwheel by hand. You should be able to turn it, but only by applying firm pressure.
If necessary, adjust the tension using the following procedure.
Adjustable gib
Adjustment screws (3)
Gib screws (3)
Figure 7-2. Adjust the adjustable gib to set the FF 206 slide tension.
1.
Turn the starwheel to move the male tool slide to about the center of the gibs.
2.
On the adjustable gib, loosen the gib screws. Turn them just enough to crack them loose.
3.
To increase the slide tension, turn the middle adjust­ment screw in (clockwise). Turn the
screw by a small amount—no more than 1/4 turn at a time.
4.
To decrease the slide tension, turn the middle adjust­ment screw out (counter-clockwise).
Turn it by a small amount—no more than 1/4 turn at a time.
E.H. Wachs
Part No. 16-MAN-01, Rev. A63
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
64
5.
Snug down the center gib screw and turn the starwheel
to check the slide tension. If necessary, loosen the
cen­ter gib screw and re-adjust the center adjustment
screw until the slide tension is correct.
6.
Loosen the center gib screw again and turn the star­
wheel to move the male tool slide to one end of the
gibs. Use the adjustment screw at that location to set
the tension. Snug the gib screw to check the tension.
7.
Loosen the gib screw by the male tool slide, then turn
the starwheel to move the slide to the other end of the
gib. Repeat the adjustment process using the adjust­
ment screw at this end of the gib.
8.
Tighten down all gib screws and check the tension
along the entire travel of the slide. Re-adjust the
ten­sion at any locations necessary.
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 8, Parts Lists and Drawings
Chapter 8
Parts Lists and Drawings
The drawings on the following pages include parts lists for all components. Refer to the drawings
and part numbers for identifying and ordering replacement parts.
E.H. Wachs
Part No. 16-MAN-01, Rev. A65
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
66
Part No. 16-MAN-01, Rev. A
E.H. Wachs
E.H. Wachs
1
90-800-02
90-800-06
13
14
1
1
3
1
1
1
1
1
1
1
1
1
11
16-005-00
16-025-00
16-082-00
16-087-00
16-301-00
16-302-00
16-304-00
16-409-00
16-MAN-01
56-099-00
66-147-00
90-050-07
1
2
3
4
5
6
7
8
9
10
11
12
QTY.
PART NUMBER
ITEM
DESCRIPTION
WEIGHT: 20.0 LB. [9.1 kg]
WRENCH, 5/64-1/4 HEX SET
(NOT SHOWN)
HEAD, ROTATING
WIPER, FELT
CASE (NOT SHOWN)
INSERT, FOAM (NOT SHOWN)
AIR MOTOR ASSEMBLY
FEED HOUSING ASSEMBLY
BEARING HOUSING ASSEMBLY
STD. MANDREL ASSEMBLY, 1.16"-4.18" I.D.
MANUAL (NOT SHOWN)
LABEL (NOT SHOWN)
LABEL, WARNING
SHCS, 1/4-20 X 3/4
WRENCH, 11/16 COMBINATION
(NOT SHOWN)
8
12
1
2
12
5
7
16-000-01
11
6
8
12
Chapter 8, Parts Lists and Drawings:
Part No. 16-MAN-01, Rev. A67
68
PART NUMBER
16-005-00
16-025-00
16-302-00
16-304-00
16-409-00
WHERE USED
66-147-00
90-050-07
16-MAN-01
16-082-00
16-087-00
56-099-00
90-800-02
90-800-06
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
1
1
1
1
1
1
1
1
8
1
1
1
1
QTY.
DESCRIPTION
WRENCH, 5/64-1/4 HEX SET
(NOT SHOWN)
5
8
DESCRIPTION
SDB 103/3 ELECT. DRIVE ASSEMBLY-110V
SDB 103/3 ELECT. DRIVE ASSEMBLY-220V
PART NO.
16-416-00
16-416-01
6
-WHERE USEDITEM
WEIGHT = 24 LB. [10.9 kg]
HEAD, ROTATING
WIPER, FELT
FEED HOUSING ASSEMBLY
BEARING HOUSING ASSEMBLY
STD. MANDREL ASSEMBLY, 1.16"-4.18" I.D.
SDB 103/3 ELECT. DRIVE ASSEMBLY
LABEL, WARNING
SHCS, 1/4-20 X 3/4
MANUAL (NOT SHOWN)
CASE (NOT SHOWN)
INSERT, FOAM (NOT SHOWN)
LABEL (NOT SHOWN)
WRENCH, 11/16 COMBINATION
(NOT SHOWN)
1
USED ON
16-000-02
16-000-03
2
6
3
5
16-000-02 (110 V) and 16-000-03 (220 V)
4
7
8
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Part No. 16-MAN-01, Rev. A
E.H. Wachs
E.H. Wachs
PART NUMBER
16-002-00
16-008-00
16-009-00
16-010-00
16-011-00
16-012-00
16-013-10
WHERE USED
90-040-05
90-040-10
90-054-08
90-074-27
90-900-64
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
1
1
2
1
1
1
1
1
4
4
4
1
4
QTY.
3
10
2
HOUSING, FEED NUT
COLLAR, KEY
KEY, MANDREL
NUT, FEED
BEARING, FEED NUT
WASHER
RETAINING RING, GROUND
LABEL, FEED NUT
SHCS, 10-24 X 1/2
SHCS, 10-24 X 1
SSS, 1/4-20 X 7/8
SSS, 3/8-16 X 3/4 NYLOCK FLAT PT.
KNOB
DESCRIPTION
9
7
6
8
5
DESCRIPTION
LABEL, FEED NUT (INCH)
LABEL, FEED NUT (MM)
PART NO.
16-036-00
16-036-01
ITEM
-WHERE USED-
1
8
4
12
16-302-00, Feed Housing Assembly
11
13
Chapter 8, Parts Lists and Drawings:
Part No. 16-MAN-01, Rev. A69
70
Part No. 16-MAN-01, Rev. A
16-001-00
16-003-00
16-006-00
16-007-00
16-027-00
16-028-00
16-029-00
16-030-00
16-031-00
26-047-00
26-096-00
26-097-00
90-027-07
90-049-05
1
2
3
4
5
6
7
8
9
10
11
12
13
14
8
PART NUMBER
ITEM
1
1
1
1
2
1
1
1
1
1
1
1
1
4
QTY.
2
HOUSING, BEARING
SHAFT, MAIN
GEAR, RING
GEAR, PINION
CUP, BEARING
CONE, BEARING
CONE W/SEAL, BEARING
BUSHING
LOCKNUT
PLATE, NAME
BEARING
RETAINING RING, EXTERNAL
KEY, 1/8 SQ X 3/4
METAL-TACK
DESCRIPTION
7
13
5
3
14
11
1
12
4
5
6
9
16-304-00, Bearing Housing Assembly
10
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
E.H. Wachs
E.H. Wachs
16-014-00
16-015-00
16-019-00
16-020-00
16-079-00
16-305-00
90-042-05
WHERE USED
1
2
3
4
5
6
7
8
7
PART NUMBER
ITEM
3
3
1
1
1
1
3
1
QTY
2
MANDREL
DRAW BAR, WELDMENT
COLLAR, NUT
LEG, CHUCK
NUT, DRAW BAR
TOOL BOX AND DIVIDER ASSEMBLY
(NOT SHOWN)
BHCS, 10-24 X 1/2
AS NOTED
DESCRIPTION
8
ITEM
PART NO.
4
8
16-021-07
16-021-05
16-021-06
16-021-04
16-021-01
16-021-02
16-021-03
EXTENSION, CHUCK LEG 1.53-1.94 [38.9-49.3mm]
EXTENSION, CHUCK LEG 1.90-2.32 [48.3-58.9mm]
EXTENSION, CHUCK LEG 2.27-2.69 [57.7-68.3mm]
EXTENSION, CHUCK LEG 2.64-3.06 [67.1-77.7mm]
EXTENSION, CHUCK LEG 3.02-3.43 [76.7-87.1mm]
EXTENSION, CHUCK LEG 3.39-3.81 [86.1-96.8mm]
EXTENSION, CHUCK LEG 3.76-4.18 [95.5-106.2mm]
DESCRIPTION
-WHERE USED-
3
16-409-00, Standard Mandrel Assembly
1
5
Chapter 8, Parts Lists and Drawings:
Part No. 16-MAN-01, Rev. A71
72
PART NUMBER
16-004-00
16-025-00
90-050-07
ITEM
1
2
3
1
1
4
QTY.
3
HEAD, ROTATING
WIPER, FELT
SHCS, 1/4-20 X 3/4
DESCRIPTION
Part No. 16-MAN-01, Rev. A
16-400-00, Standard Tool Head
1
3.125
2
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
E.H. Wachs
PART NUMBER
16-050-00
16-051-00
16-052-00
16-055-00
16-056-00
16-057-00
16-058-00
16-059-00
90-059-28
90-800-68
90-904-03
WHERE USED
WHERE USED
ITEM
1
2
3
4
5
6
7
8
9
10
E.H. Wachs
11
12
13
3
2
1
1
1
1
1
2
1
1
1
1
2
QTY.
2
MANDREL, ELBOW
CONE
ROD, DRAW
SCREW, 3/8 DIA. ADJUSTABLE
NUT, DRAW BAR
FIXTURE, ALIGNMENT
BLOCK, WOOD LEG (NOT SHOWN)
STICKER, LEG RANGE (NOT SHOWN)
SSS, 1/4-20 X 3/4 BRASS TIP
WRENCH, 3/4 X 5/8 BOX RATCHET
(NOT SHOWN)
SSS, 6-32 X 3/8 NYLON
LEG
LEG, ADJUSTABLE
DESCRIPTION
13
12
3
ITEM
PART NO.
DESCRIPTION
16-054-07
12
LEG, ADJUSTABLE (1.424)
LEG, ADJUSTABLE (1.574)
LEG, ADJUSTABLE (1.124)
LEG, ADJUSTABLE (1.274)
16-054-04
16-054-05
16-054-06
LEG (1.694)
LEG, ADJUSTABLE (.824)
LEG, ADJUSTABLE (.974)
LEG (1.094)
LEG (1.244)
LEG (1.394)
LEG (1.544)
LEG (.794)
LEG (.944)
16-053-07
16-054-02
16-054-03
16-053-05
16-053-06
16-053-04
16-053-01
16-053-02
16-053-03
-WHERE USED-
11
13
4
6
9
16-414-00, Independent Fitting Mandrel Assembly
1
5
Chapter 8, Parts Lists and Drawings:
Part No. 16-MAN-01, Rev. A73
74
16-062-00
16-063-00
16-064-00
16-067-00
16-069-00
16-070-01
16-084-00
90-050-12
16-068-00
16-070-02
1
2
3
4
5
6
7
8
9
10
4
PART NUMBER
ITEM
1
1
1
3
1
1
1
4
3
1
QTY.
3
HEAD, ROTATING-7/8
MANDREL, 7/8"
WELDMENT, DRAW BAR
LEG, .88 - 1.11
BUSHING
O-RING (-114) URETHANE SHORE 90
NUT, DRAW BAR
SHCS, 1/4-20 X 1-1/4
LEG, 1 - 1-1/4 (NOT SHOWN)
O-RING (-116) (NOT SHOWN)
DESCRIPTION
6
5
8
1
16-401-00, Small Diameter Conversion Kit
2
7
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Part No. 16-MAN-01, Rev. A
E.H. Wachs
E.H. Wachs
PART NUMBER
16-301-00
16-302-00
16-304-00
16-404-00
16-414-00
66-147-00
90-050-07
16-MAN-01
16-025-00
16-082-00
16-087-00
56-099-00
56-191-00
90-800-02
90-800-06
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
1
1
1
1
1
1
1
7
1
2
1
1
1
1
QTY.
WEIGHT: 28.5 LB. [12.9 kg]
WRENCH, 5/64-1/4 HEX SET
(NOT SHOWN)
AIR MOTOR ASSEMBLY
FEED HOUSING ASSEMBLY
BEARING HOUSING ASSEMBLY
SLIDE ASSEMBLY, SINGLE POINT
SDB 103 ELB. MANDREL ASSEMBLY
LABEL, WARNING
SHCS, 1/4-20 X 3/4
MANUAL (NOT SHOWN)
WIPER, FELT (NOT SHOWN-SHIPPED LOOSE)
CASE (NOT SHOWN)
INSERT, FOAM (NOT SHOWN)
LABEL (NOT SHOWN)
WRENCH, TORX (NOT SHOWN)
WRENCH, 11/16 COMBINATION
(NOT SHOWN)
DESCRIPTION
5
4
7
1
3
2
16-000-FF, FF 206 Flange Facer Assembly
6
7
Chapter 8, Parts Lists and Drawings:
Part No. 16-MAN-01, Rev. A75
76
2
1
1
1
1
1
1
6
1
2
6
2
1
2
1
1
1
5
6
2
7
6
1
16-025-00
16-037-00
16-038-00
16-039-00
16-040-00
16-041-00
16-042-00
16-044-00
16-045-00
43-022-00
52-140-00
56-066-00
56-067-00
56-190-00
60-702-00
90-019-43
90-026-55
90-050-07
90-050-08
90-050-10
90-054-05
90-057-53
90-075-07
90-800-31
90-800-69
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
1
1
QTY.
PART NUMBER
ITEM
DESCRIPTION
WRENCH, T-15 TORX
(NOT SHOWN)
WIPER, FELT
PLATE, MOUNTING
SLIDE, MALE
PLATE, BACKING
SCREW, FEED
BLOCK, FEED SCREW
HOLDER, TOOL
TRIP
WELDMENT, TRIP COLLAR
BEARING, FEED SCREW
PLUNGER, BALL
GIB
WHEEL, STAR
SCREW, INSERT
INSERT, TOOL
KEY, 3/32 X 3/8 WOODRUFF
1/8" X 1/2" PIN
SHCS, 1/4-20 X 3/4
SHCS, 1/4-20 X 7/8
SHCS, 1/4-20 x 1
SSS, 1/4-20 X 1/2
SHSB, 1/4 X 3/8
NUT, 3/8-24 SLOTTED
WRENCH, 9/16 COMBINATION
(NOT SHOWN)
19
7
12
15
20
16
6
14
17
5
3
19
10
23
10
21
13
18
12
4
2
Part No. 16-MAN-01, Rev. A
21
8
18
16-404-00, FF 206 Flange Facer Slide Assembly
1
22
9
11
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
E.H. Wachs
E.H. Wachs
PART NUMBER
16-005-00
16-025-00
16-409-00
90-050-07
ITEM
1
2
3
4
1
1
1
4
QTY.
3
HEAD, ROTATING
WIPER, FELT
STD. MANDREL ASSEMBLY, 1.16"-4.18" I.D.
SHCS, 1/4-20 X 3/4
DESCRIPTION
2
4.750
16-420-00, FF 206 to SDB 103 Conversion Kit
4
1
Chapter 8, Parts Lists and Drawings:
Part No. 16-MAN-01, Rev. A77
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
ITEM
PART NUMBER
QTY.
DESCRIPTION
1
2
3
4
5
6
16-026-00
16-060-00
90-029-43
90-058-58
90-401-02
90-401-03
1
1
1
1
1
1
MOTOR, AIR
VALVE, SPEED CONTROL
KEY, 1/8 X 1/2 8630 ALLOY STL WOODRUFF
NIPPLE, 1/4 HEX H.P.
LABEL, PRESSURE
LABEL, EAR AND EYE PROTECTION
2
4
5
1
6
3
16-301-00, Air Motor Assembly
78
Part No. 16-MAN-01, Rev. A
E.H. Wachs
E.H. Wachs
QTY.
1
1
1
1
1
1
1
1
1
7
1
3
1
1
PART NUMBER
11-103-00
16-073-00
16-074-00
16-075-00
16-076-00
16-077-00
16-078-00
WHERE USED
26-126-01
90-020-15
90-027-07
90-050-08
90-060-12
90-401-03
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
2
GEARBOX, PLANETARY OUTPUT
HOUSING, GEAR
SHAFT, OUTPUT
HOUSING, REAR
RING, RETAINING
RING, RETAINING
BEARING
MOTOR, METABO
COUPLING, INPUT
SHCS #8-32 x 1.375
KEY, 1/8 SQ X 3/4
SHCS, 1/4-20 X 7/8
SHCS, 5/16-18 X 1-1/4
LABEL, EAR AND EYE PROTECTION
DESCRIPTION
12
6
7
11
5
3
MOTOR, METABO 110V
MOTOR, METABO 220V
20-031-00
30-031-01
8
1
DESCRIPTION
PART NO.
ITEM
-WHERE USED-
4
14
10
13
SDB 103 Electric Drive Assembly
16-416-00, 110 V
16-416-01, 220 V
9
8
Chapter 8, Parts Lists and Drawings:
Part No. 16-MAN-01, Rev. A79
80
PART NUMBER
05-061-01
26-080-00
26-083-00
90-050-07
90-055-01
90-055-52
90-055-56
90-400-01
ITEM
1
2
3
4
5
6
7
8
1
1
1
2
2
2
4
2
QTY.
4
7
HOSE WHIP, 6-FT. X 1/2" DIA.
WELDMENT, A.T.M.
FILTER REGULATOR-LUBRICATOR (FRL)
SHCS, 1/4-20 X 3/4
NUT, 1/4-20 HEX
WASHER, 1/4 SPLIT RING
WASHER, #12 FLAT
LABEL, WACHS CIRCLE LOGO 1.625
DESCRIPTION
3
1
8
2
7
26-407-00, Air Caddy Assembly
6
5
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 9, Accessories and Spare Parts
Chapter 9
Accessories and Spare Parts
Accessories
The following accessories are available for the SDB 103 and FF 206.
Table 1: ADB 103/FF 206 Accessories
Part Number
Description
16-401-00
Small diameter conversion kit
16-414-00
Independent fitting mandrel
16-411-00
Collet mandrel for pipe (special order)
16-412-00
Collet mandrel for tube (special order)
16-421-00
FF 206 conversion kit (for SDB 103)
16-420-00
SDB 103 conversion kit (for FF 206)
16-404-00
FF 206 tool slide
72-405-01
3.25” diameter wedgelock tool head
72-405-00
4.25” diameter wedgelock tool head
16-301-00
Air drive
16-416-00
110 V electric drive
16-416-01
220 V electric drive
26-407-00
Air treatment module
E.H. Wachs
Part No. 16-MAN-01, Rev. A81
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Tooling
The following tables list tooling for the SDB 103 and FF 206.
Table 2: SDB 103 Facing Tools
Part Number
Description
26-410-02
Standard facing tool
26-410-03
High-range facing tool
26-410-04
Carbide-tipped facing tool
26-SPT-01
Custom high-speed steel facing tool—customer specifications required
Table 3: SDB 103 Beveling Tools
Part Number
Description
26-411-01
37.5° low-range bevel tool
26-411-02
37.5° medium-range bevel tool
26-411-03
37.5° high-range bevel tool
26-411-04
37.5° carbide bevel tool
26-713-00
20°, 3/32” radius “J” bevel tool for 1.35” to 4.00” I.D. (use with 26-410-02 facing tool for 0.030” land
extension)
26-SPT-02
Custom single-angle bevel tool—customer specifi­cations required
26-SPT-06
Custom high-speed steel “J” bevel tool—customer specifications required
26-413-01
37.5° universal low-range beveling and facing tool
26-413-02
37.5° universal high-range beveling and facing tool
26-SPT-04
Custom high-speed steel beveling tool—customer specifications required
Table 4: SDB 103 I.D. Counterboring Tools
Part Number
Description
26-412-01
Low-range I.D. deburring tool
26-412-02
Medium-range I.D. deburring tool
26-412-03
High-range I.D. deburring tool
26-426-00
30° taper counterbore and facing tool
26-SPT-03
Custom high-speed steel I.D. deburring tool—cus­tomer specifications required
26-SPT-05
Custom high-speed steel counterboring tool—cus­tomer specifications required
82
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 9, Accessories and Spare Parts: Tooling
Table 5: FF 206 Single-Point Tooling
Part Number
Description
16-701-00
Flange facing carbide insert tool holder kit (includes tool wrench and 5 tool inserts)
60-702-00
Carbide insert for beveling and flange facing
See the drawing below for the single-point tool holder.
1
4
2
16-701-00, Flange Facing Insert Holder
E.H. Wachs
Part No. 16-MAN-01, Rev. A83
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
84
Part No. 16-MAN-01, Rev. A
E.H. Wachs
Chapter 10, Ordering Information
Chapter 10
Ordering Information
To place an order, request service, or get more detailed information on any E.H. Wachs products,
call us at one of the following numbers:
U.S.800-323-8185
International:847-537-8800
You can also visit our Web site at:
www.ehwachs.com
Ordering Replacement Parts
When ordering parts, refer to the drawings and parts lists in Chapter 8. Please provide the part
description and part number for all parts you are ordering.
Repair Information
Please call us for an authorization number before returning any equipment for repair or factory
service. We will advise you of shipping and handling. When you send the equip­ment, please
include the following information:
• Your name/company name
• Your address
• Your phone number
• A description of the problem or the work to be done.
Before we perform any repair, we will estimate the work and inform you of the cost and the time to
complete it.
E.H. Wachs
Part No. 16-MAN-01, Rev. A85
SDB-103 Small Diameter Beveler and FF 206 Flange Facer
Warranty Information
Enclosed with the manual is a warranty card. Please fill out the registration card and return to E.H.
Wachs. Retain the owner’s registration record and warranty card for your information.
Return Goods Address
Return equipment for repair to the following address.
E.H. Wachs
600 Knightsbridge Parkway
Lincolnshire, Illinois 60069 USA
86
Part No. 16-MAN-01, Rev. A
E.H. Wachs
600 Knightsbridge Parkway • Lincolnshire, IL 60069
847-537-8800 • www.wachsco.com